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Z IGNITION SYSTEMS 8D - 1

IGNITION SYSTEMS

CONTENTS
page page

COMPONENT IDENTIFICATION/SYSTEM DIAGNOSTICS/SERVICE PROCEDURES . . . . . . . 8


OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . 35
COMPONENT REMOVAL/INSTALLATION . . . . . 21 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 38

COMPONENT IDENTIFICATION/SYSTEM OPERATION

INDEX
page page

Automatic Shut Down Relay (ASD) Relay . . . . . . . . 1 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 4


Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . 2 Intake Manifold Charge Air Temperature Sensor . . . 5
Crankshaft Position Sensor . . . . . . . . . . . . . . . . . . 2 Manifold Absolute Pressure (MAP) Sensor . . . .. . . 6
Distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Powertrain Control Module (PCM) . . . . . . . . . .. . . 6
Engine Coolant Temperature Sensor . . . . . . . . . . . . 5 Throttle Position Sensor . . . . . . . . . . . . . . . . . .. . . 7
General Information . . . . . . . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION IGNITION SYSTEMS


Throughout this group, references are made to par- Two different ignition operating systems are used.
ticular vehicle models by alphabetical designation or One system is used on the 4.0L 6 cylinder engine. The
by the particular vehicle nameplate. A chart showing other is used on the 5.2L V-8 engine. Similarities and
a breakdown of alphabetical designations is included differences between the two systems will be dis-
in the Introduction group at the beginning of this cussed.
manual. A multi-port, fuel injected engine is used on all
This section of the group, Component models. The ignition system is controlled by the Pow-
Identification/System Operation, will discuss ignition ertrain Control Module (PCM) on all engines. The
system operation and will identify ignition system PCM was formerly referred to as the SBEC or engine
components. controller.
For diagnostic procedures and adjustments, refer to The ignition system consists of:
the Diagnostics/Service Procedures section of this • Spark Plugs
group. • Ignition Coil
For removal and installation of ignition system • Secondary Ignition Cables
components, refer to the Component • Ignition distributor (contains rotor and camshaft
Removal/Installation section of this group. position sensor)
For other useful information, refer to On-Board Di- • Powertrain Control Module (PCM)
agnostics in the General Diagnosis sections of Group • Crankshaft Position Sensor
14, Fuel System in this manual.
For operation of the DRB II Diagnostic Scan Tool, AUTOMATIC SHUT DOWN RELAY (ASD) RELAY
refer to the appropriate Powertrain Diagnostic Proce- The automatic shut down (ASD) relay is located in
dures service manual. the Power Distribution Center (PDC) near the battery
An Ignition specifications section is included at the (Fig. 1). As one of its functions, it will supply battery
end of this group. A general Maintenance Schedule voltage to the ignition coil. The ground circuit for the
(mileage intervals) for ignition related items can be ASD relay is controlled by the Powertrain Control
found in Group 0, Lubrication and Maintenance. This Module (PCM). The PCM regulates ASD relay opera-
schedule can also be found in the Owners Manual. tion by switching the ground circuit on-and-off.
8D - 2 IGNITION SYSTEMS Z

Fig. 3 Camshaft Position Sensor—5.2L Engine


between fuel injection and spark events. It is also
used to synchronize the fuel injectors with their re-
spective cylinders.
When the leading edge of the pulse ring (shutter)
Fig. 1 Power Distribution Center enters the sync signal generator, the following occurs:
The interruption of magnetic field causes the voltage
CAMSHAFT POSITION SENSOR to switch high resulting in a sync signal of approxi-
The camshaft position sensor is located in the igni-
mately 5 volts.
tion distributor (Figs. 2 or 3) on all engines.
When the trailing edge of the pulse ring (shutter)
leaves the sync signal generator, the following occurs:
The change of the magnetic field causes the sync
signal voltage to switch low to 0 volts.
For component testing, refer to the
Diagnostics/Service Procedures section of this group.
For removal and installation of this component,
refer to the Component Removal/Installation section
of this group.

CRANKSHAFT POSITION SENSOR


On 4.0L engines, the crankshaft position sensor is
mounted to the transmission bellhousing at the
left/rear side of the engine block (Fig. 4).
On 5.2L engines, the sensor is bolted to the top of
cylinder block near the rear of the right cylinder head
(Fig. 5).
Engine speed and crankshaft position are provided
through the crankshaft position sensor. The sensor
generates pulses that are the input sent to the Power-
train Control Module (PCM). The PCM interprets the
sensor input to determine the crankshaft position.
Fig. 2 Camshaft Position Sensor—4.0L Engine The PCM then uses this position, along with other
inputs, to determine injector sequence and ignition
The camshaft position sensor contains a hall effect
timing.
device called a sync signal generator to generate a
The sensor is a hall effect device combined with an
fuel sync signal. This sync signal generator detects a
internal magnet. It is also sensitive to steel within a
rotating pulse ring (shutter) on the distributor shaft.
certain distance from it.
The pulse ring rotates 180 degrees through the sync
signal generator. Its signal is used in conjunction
with the crankshaft position sensor to differentiate
Z IGNITION SYSTEMS 8D - 3

For component testing, refer to the


Diagnostics/Service Procedures section of this group.
For removal and installation of this sensor, refer to
the Component Removal/Installation section of this
group.

Fig. 4 Crankshaft Position Sensor—4.0L Engine

Fig. 6 Sensor Operation—4.0L Engine


SENSOR OPERATION—5.2L ENGINE
On 5.2L engines, the flywheel/drive plate has 8
single notches, spaced every 45 degrees, at its outer
edge (Fig. 7).
The notches cause a pulse to be generated when
they pass under the sensor. The pulses are the input
to the PCM. For each engine revolution, there are 8
pulses generated on 5.2L V-8 engines.
The engine will not operate if the PCM does not
receive a crankshaft position sensor input.
For component testing, refer to the
Fig. 5 Crankshaft Position Sensor—5.2L Diagnostics/Service Procedures section of this group.
Engine—Typical For removal and installation of this component,
SENSOR OPERATION—4.0L ENGINE refer to the Component Removal/Installation section
The flywheel/drive plate has groups of four notches of this group.
at its outer edge. On 4.0L engines there are three sets
of notches (Fig. 6). DISTRIBUTORS
The notches cause a pulse to be generated when All engines are equipped with a camshaft driven
they pass under the sensor. The pulses are the input mechanical distributor, containing a shaft driven dis-
to the PCM. For each engine revolution there are tributor rotor. All distributors are equipped with an
there are 3 groups of four pulses generated on 4.0L 6 internal camshaft position (fuel sync) sensor. This
cylinder engines. sensor provides fuel injection synchronization and cyl-
The trailing edge of the fourth notch, which causes inder identification.
the pulse, is four degrees before top dead center The distributors on the 4.0L and 5.2L engines do
(TDC) of the corresponding piston. not have built in centrifugal or vacuum assisted ad-
The engine will not operate if the PCM does not vance. Base ignition timing and all timing advance is
receive a crankshaft position sensor input. controlled by the Powertrain Control Module
8D - 4 IGNITION SYSTEMS Z

the base timing and adjust the ignition timing ad-


vance. This is done to meet changing engine operat-
ing conditions.
The ignition coil is not oil filled. The windings are
embedded in an epoxy compound. This provides heat
and vibration resistance that allows the ignition coil
to be mounted on the engine.
On 4.0L 6 cylinder engines, the ignition coil is
mounted to a bracket on the side of the engine (Fig.
8).
On 5.2L V-8 engines, the ignition coil is mounted to
a bracket at the front of the right cylinder head (Fig.
9). This bracket is also used to mount the automatic
belt tensioner.

Fig. 7 Sensor Operation—5.2L Engine


(PCM). Because ignition timing is controlled by the
PCM, base ignition timing is not adjustable on
any of these engines.
On the 4.0L 6 cylinder engine, the distributor is
locked in place by a notch on the distributor housing.
The distributor holddown clamp bolt passes through
this notch when installed. Because the distributor
position is locked when installed, its rotational posi- Fig. 8 Ignition Coil—4.0L Engine
tion can not be changed. Do not attempt to modify
the distributor housing to get distributor rota-
tion. Distributor position will have no effect on
ignition timing.
On the 5.2L V-8 engine, the distributor is held to
the engine in the conventional method using a hold-
down clamp and bolt. Although the distributor on
the 5.2L engine can be rotated, it will have no
effect on ignition timing.
All distributors contain an internal oil seal that
prevents oil from entering the distributor housing.
The seal is not serviceable.
For component testing, refer to the
Diagnostics/Service Procedures section of this group.
For removal and installation of this component,
refer to the Component Removal/Installation section
of this group.
Fig. 9 Ignition Coil—5.2L Engine—Typical
IGNITION COIL For component testing, refer to the
Battery voltage is supplied to the ignition coil posi-
tive terminal from the ASD relay. Diagnostics/Service Procedures section of this group.
The Powertrain Control Module (PCM) opens and For removal and installation of this component,
closes the ignition coil ground circuit for ignition coil refer to the Component Removal/Installation section
operation. of this group.
Base ignition timing is not adjustable. By con-
trolling the coil ground circuit, the PCM is able to set
Z IGNITION SYSTEMS 8D - 5

ENGINE COOLANT TEMPERATURE SENSOR refer to the Component Removal/Installation section


The sensor provides an input voltage to the Power- of this group.
train Control Module (PCM) relating coolant tempera-
ture. The PCM uses this input, along with inputs INTAKE MANIFOLD CHARGE AIR TEMPERATURE
from other sensors, to determine injector pulse width SENSOR
and ignition timing. As coolant temperature varies, The sensor element extends into the intake mani-
the coolant temperature sensor resistance will fold air stream. It provides an input voltage to the
change, resulting in a different input voltage to the Powertrain Control Module (PCM) indicating intake
PCM. manifold air temperature. The input from this sensor
When the engine is cold, the PCM will operate in is used along with inputs from other sensors to deter-
the Open Loop Cycle. It will demand slightly richer mine injector pulse width. As the temperature of the
air-fuel mixtures and higher idle speeds, until normal air-fuel stream in the manifold varies, the sensor
operating temperatures are reached. Refer to Modes resistance will change. This will result in a different
Of Operation in Group 14, Fuel System for a descrip- input voltage to the PCM. For more information, refer
tion of Open and Closed Loop operation. to Group 14, Fuel System.
This sensor is installed in the thermostat housing This sensor is installed in the intake manifold (Fig.
on 4.0L 6 cylinder engines (Fig. 10). 12, 4.0L engine or Fig. 13, 5.2L engine).
This sensor is installed in the intake manifold near For component testing, refer to the
the thermostat housing on 5.2L V-8 engines (Fig. 11).
For component testing, refer to the

Fig. 12 Sensor Location—4.0L Engine

Fig. 10 Coolant Temperature Sensor—4.0L Engine

Fig. 13 Sensor Location—5.2L Engine—Typical


Diagnostics/Service Procedures section of this group.
Fig. 11 Coolant Temperature Sensor—5.2L Engine
Diagnostics/Service Procedures section of this group.
For removal and installation of this component,
8D - 6 IGNITION SYSTEMS Z

For removal and installation of this component,


refer to the Component Removal/Installation section
of this group.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR


The MAP sensor reacts to absolute pressure in the
intake manifold and provides an input voltage to the
Powertrain Control Module (PCM). As engine load
changes, manifold pressure varies, causing the MAP
sensor voltage to change. This change results in a
different input voltage to the PCM. The input voltage
level supplies the PCM with information. This relates
to ambient barometric pressure during engine
start-up (cranking) and to engine load while the en-
gine is running. The PCM uses this input, along with
inputs from other sensors, to adjust air-fuel mixture.
For more information, refer to Group 14, Fuel Sys- Fig. 15 MAP Sensor—5.2L Engine
tem.
On 4.0L 6 cylinder engines, the MAP sensor is
mounted on the dash panel (Fig. 14). It is connected
to the throttle body with a vacuum hose and to the
PCM electrically.
On 5.2L V-8 engines, the MAP sensor is mounted to
the throttle body (Fig. 15). It is connected to the
throttle body with an L-shaped rubber fitting and to
the PCM electrically.

Fig. 16 PCM Location


This is done to adjust ignition timing, both initial
(base) and advance, for changing engine operating
Fig. 14 MAP Sensor—4.0L Engine conditions.
For component testing, refer to the The amount of electronic spark advance provided by
Diagnostics/Service Procedures section of this group. the PCM is determined by five input factors: Coolant
For removal and installation of this component, temperature, engine rpm, intake manifold air tem-
refer to the Component Removal/Installation section perature, manifold absolute pressure and throttle po-
of this group. sition.
For removal and installation of this component,
POWERTRAIN CONTROL MODULE (PCM) refer to the Component Removal/Installation section
The PCM (formerly called the SBEC or engine con- of this group.
troller) is located in the right/rear side of the engine For diagnostics, refer to the appropriate Powertrain
compartment (Fig. 16). Diagnostic Procedures service manual for operation of
The ignition system is controlled by the PCM.
the DRB II scan tool.
Base ignition timing by rotation of distributor
is not adjustable. The PCM opens and closes the
ignition coil ground circuit to operate the ignition coil.
Z IGNITION SYSTEMS 8D - 7

THROTTLE POSITION SENSOR


The sensor is mounted on the throttle body (Figs.
17 or 18). It is connected to the throttle blade shaft.
The sensor is a variable resistor. It provides the Pow-
ertrain Control Module (PCM) with an input signal
(voltage) that represents throttle blade position. As
the position of the throttle blade changes, the resis-
tance of the sensor changes.

Fig. 18 Throttle Position Sensor—5.2L


Engine—Typical
open throttle. Along with inputs from other sensors,
Fig. 17 Throttle Position Sensor—4.0L Engine
the PCM uses the sensor input to determine current
The PCM supplies approximately 5 volts to the engine operating conditions. It also will adjust fuel
sensor. The sensor output voltage (input signal to the injector pulse width and ignition timing.
PCM) represents the throttle blade position. The For component testing, refer to the
PCM receives an input signal voltage from the sensor. Diagnostics/Service Procedures section of this group.
This will vary in an approximate range of from 1 volt For removal and installation of this component,
at minimum throttle opening (idle), to 4 volts at wide refer to the Component Removal/Installation section
of this group.
8D - 8 IGNITION SYSTEMS Z

DIAGNOSTICS/SERVICE PROCEDURES

INDEX
page page

Automatic Shut Down (ASD) Relay . . . . . . . . . . . . . 8 Ignition Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . 14


Camshaft Position Sensor Test . . . . . . . . . . . . . . . . 8 Intake Manifold Charge Air Temperature Sensor
Crankshaft Position Sensor Test . . . . . . . . . . . . . . . 9 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Distributor Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Manifold Absolute Pressure (MAP) Sensor Test . . . 15
Distributor Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Oxygen Sensor Tests . . . . . . . . . . . . . . . . . . . . . . 20
Engine Coolant Temperature Sensor Test . . . . . . . 11 Powertrain Control Module (PCM) . . . . . . . . . . . . . 16
General Information . . . . . . . . . . . . . . . . . . . . . . . . 8 Spark Plug Secondary Cables . . . . . . . . . . . . . . . 18
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Ignition Secondary Circuit Diagnosis . . . . . . . . . . . 13 Throttle Position Sensor Test . . . . . . . . . . . . . . . . 20

GENERAL INFORMATION (2) Connect the negative (-) voltmeter lead into the
This section of the group, Diagnostics/Service Proce- ground wire. For wire identification, refer to Group
dures, will discuss basic ignition system diagnostics 8W, Wiring Diagrams.
and service adjustments. (3) Set the voltmeter to the 15 Volt DC scale.
For system operation and component identification, 4.0L Engines: Remove distributor cap. Rotate
refer to the Component Identification/System Opera- (crank) engine with starter until pulse ring (Fig. 1)
tion section of this group. enters the magnetic pickup on camshaft position sen-
For removal or installation of ignition system com- sor. Distributor rotor should be pointed in 9 o’clock
ponents, refer to the Component Removal/Installation position. The movable pulse ring should now be
section of this group. within the sensor pickup.
For other useful information, refer to On-Board Di- 5.2L Engines: Remove coil high-tension cable and
agnostics in the General Diagnosis sections of Group
all spark plug cables at distributor cap. Note and
14, Fuel System in this manual.
mark position of cables before removal (Fig. 2). Re-
For operation of the DRB II Diagnostic Scan Tool,
move distributor cap from distributor (two screws).
refer to the appropriate Powertrain Diagnostic Proce-
Rotate (crank) the engine until the distributor rotor is
dures service manual.
pointed towards the rear of vehicle. The movable
AUTOMATIC SHUT DOWN (ASD) RELAY pulse ring should now be within the sensor pickup.
Refer to Relays—Operation/Testing in the Group
14, Fuel System section of this service manual.

CAMSHAFT POSITION SENSOR TEST


The camshaft position sensor is located in the dis-
tributor on all engines.
To perform a complete test of this sensor and its
circuitry, refer to the DRB II diagnostic scan tool. Also
refer to the appropriate Powertrain Diagnostics Pro-
cedures manual. To test the sensor only, refer to the
following:

4.0L OR 5.2L ENGINE


For this test, an analog voltmeter is needed.
Do not remove the distributor connector from the
distributor. Using small paper clips, insert them into
the backside of the distributor wire harness connector
to make contact with the terminals. Be sure that the
connector is not damaged when inserting the paper
clips. Attach voltmeter leads to these paper clips.
(1) Connect the positive (+) voltmeter lead into the
sensor output wire. This is at done the distributor
wire harness connector. For wire identification, refer
to Group 8W, Wiring Diagrams. Fig. 1 Pulse Ring/Rotor Position—4.0L Engine
Z IGNITION SYSTEMS 8D - 9

For system operation and component identification,


refer to the Component Identification/System Opera-
tion section of this group.

CRANKSHAFT POSITION SENSOR TEST


To perform a complete test of this sensor and its
circuitry, refer to the DRB II diagnostic scan tool. Also
refer to the appropriate Powertrain Diagnostics Pro-
cedures manual. To test the sensor only, refer to the
following:
On the 4.0L engine, the sensor is located on the
transmission bellhousing at the left/rear side of the
engine block (Fig. 3).
On the 5.2L engine, the sensor is located on the top
of cylinder block near the rear of right cylinder head
(Fig. 4).
Fig. 2 Engine Firing Order—5.2L Engine (1) Near the rear of intake manifold, disconnect
sensor pigtail harness connector from main wiring
(4) Turn ignition key to ON position. Voltmeter
harness.
should read approximately 5.0 volts.
(5) If voltage is not present, check the voltmeter
leads for a good connection.
(6) If voltage is still not present, check for voltage
at the supply wire. For wire identification, refer to
Group 8W, Wiring Diagrams.
(7) If voltage is not present at supply wire, check
for voltage at pin 7 of Powertrain Control Module
(PCM) 60-way connector. Leave the PCM connector
connected for this test.
(8) If voltage is still not present, perform vehicle
test using the DRB II diagnostic scan tool.
(9) If voltage is present at pin 7, but not at the
supply wire:
(a) Check continuity between the supply wire.
This is checked between the distributor connector
and pin 7 at the PCM. If continuity is not present,
repair the harness as necessary.
Fig. 3 Crankshaft Position Sensor—4.0L Engine
(b) Check for continuity between the camshaft
position sensor output wire and pin 44 at the PCM. (2) Place an ohmmeter across terminals B and C
If continuity is not present, repair the harness as (Fig. 5). Ohmmeter should be set to 1K-to-10K scale
necessary. for this test. The meter reading should be open (no
(c) Check for continuity between the ground cir- resistance). Replace sensor if a low resistance is indi-
cuit wire at the distributor connector and ground. If cated.
continuity is not present, repair the harness as
necessary. DISTRIBUTOR CAP
(10) While observing the voltmeter, crank the en- INSPECTION
gine with ignition switch. The voltmeter needle Remove the distributor cap and wipe it clean with a
should fluctuate between 0 and 5 volts while the dry lint free cloth. Visually inspect the cap for cracks,
engine is cranking. This verifies that the camshaft carbon paths, broken towers, or damaged rotor button
position sensor in the distributor is operating prop- (Figs. 6 and 7). Also check for white deposits on the
erly and a sync pulse signal is being generated. inside (caused by condensation entering the cap
If sync pulse signal is not present, replacement of through cracks). Replace any cap that displays
the camshaft position sensor is necessary. charred or eroded terminals. The machined surface of
For removal or installation of ignition system com- a terminal end (faces toward rotor) will indicate some
ponents, refer to the Component Removal/Installation evidence of erosion from normal operation. Examine
section of this group. the terminal ends for evidence of mechanical interfer-
ence with the rotor tip.
8D - 10 IGNITION SYSTEMS Z

Fig. 6 Cap Inspection—External—Typical

Fig. 4 Crankshaft Position Sensor—5.2L


Engine—Typical

Fig. 7 Cap Inspection—Internal—Typical

Fig. 5 Crankshaft Position Sensor Connector


If replacement of the distributor cap is necessary,
transfer spark plug cables from the original cap to the
new cap. This should be done one cable at a time.
Each cable is installed onto the tower of the new cap
that corresponds to its tower position on the original
cap. Fully seat the cables onto the towers. If neces-
sary, refer to the Engine Firing Order diagrams (Figs.
8 or 9).

DISTRIBUTOR ROTOR
Visually inspect the rotor (Figs. 10 or 11) for cracks, Fig. 8 Engine Firing Order—4.0L Engine
evidence of corrosion, or the effects of arcing on the ence noise suppression, will appear charred. This is
metal tip. Also check for evidence of mechanical inter- normal. Do not remove the
ference with the cap. Some charring is normal on the
end of the metal tip. The silicone-dielectric-varnish-
compound applied to the rotor tip for radio interfer-
Z IGNITION SYSTEMS 8D - 11

Fig. 9 Engine Firing Order—5.2L Engine


charred compound. Test the spring for insufficient
tension. Replace a rotor that displays any of these
adverse conditions.
Fig. 11 Rotor Inspection—5.2L Engine—Typical

Fig. 12 Ignition Coil—4.0L Engine


If the ignition coil is being replaced, the secondary
spark plug cable must also be checked. Replace cable
if it has been burned or damaged.
Arcing at the tower will carbonize the cable nipple,
Fig. 10 Rotor Inspection—4.0L Engine—Typical
which if it is connected to a new ignition coil, will
IGNITION COIL cause the coil to fail.
To perform a complete test of the ignition coil and If the secondary coil cable shows any signs of dam-
its circuitry, refer to the DRB II diagnostic scan tool. age, it should be replaced with a new cable and new
Also refer to the appropriate Powertrain Diagnostics terminal. Carbon tracking on the old cable can cause
Procedures manual. To test the coil only, refer to the arcing and the failure of a new ignition coil.
following:
The ignition coil (Figs. 12 or 13) is designed to ENGINE COOLANT TEMPERATURE SENSOR TEST
operate without an external ballast resistor. To perform a complete test of this sensor and its
Inspect the ignition coil for arcing. Test the coil circuitry, refer to the DRB II diagnostic scan tool.
according to coil tester manufacturer’s instructions.
Test the coil primary and secondary resistance. Re-
place any coil that does not meet specifications. Refer
to the Ignition Coil Resistance chart.
8D - 12 IGNITION SYSTEMS Z

Fig. 13 Ignition Coil—5.2L Engine Fig. 14 Coolant Temperature Sensor—4.0L Engine


IGNITION COIL RESISTANCE

Also refer to the appropriate Powertrain Diagnostics


Procedures manual. To test the sensor only, refer to
the following:
4.0L Engines: The sensor is installed in the thermo-
stat housing (Fig. 14).
5.2L Engines: The sensor is located in a water
passage of the intake manifold next to the thermostat
housing (Fig. 15).
(1) Disconnect wire harness connector from sensor
(Figs. 14 or 15). On 5.2L engines with air condition-
ing, do not pull directly on wiring harness. Fabricate
an L-shaped hook tool from a coat hanger (approxi-
mately eight inches long). Place the hook part of tool
under the connector for removal. The connector is
snapped onto the sensor. It is not equipped with a
lock type tab. Fig. 15 Coolant Temperature Sensor—5.2L Engine
(2) Test the resistance of the sensor with a high
input impedance (digital) volt-ohmmeter. The resis- terminal. Also check continuity between wire harness
tance should be less than 1340 ohms at normal en- terminal-4 to the sensor connector terminal. Repair
gine operating idle temperature. For resistance val- the wire harness if an open circuit is indicated.
ues, refer to the Sensor Resistance chart. Replace the
sensor if it is not within the range of resistance
specified in the chart.
(3) Test continuity of the wire harness. This is done
between Powertrain Control Module (PCM) wire har-
ness connector terminal-2 and the sensor connector
Z IGNITION SYSTEMS 8D - 13

SENSOR RESISTANCE (OHMS) THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR
LOOSE FITTING CLOTHING.

(2) Rotate (crank) the engine with the starter mo-


tor and observe the cable terminal for a steady arc. If
steady arcing does not occur, inspect the secondary
coil cable. Refer to Spark Plug Cables in this group.
Also inspect the distributor cap and rotor for cracks
or burn marks. Repair as necessary. If steady arcing
occurs, connect ignition coil cable to the distributor
cap.
(3) Remove a cable from one spark plug.
(4) Using insulated pliers, hold the cable terminal
approximately 12 mm (1/2 in.) from the engine cylin-
der head or block while rotating the engine with the
starter motor. Observe the spark plug cable terminal
for an arc. If steady arcing occurs, it can be expected
that the ignition secondary system is operating cor-
rectly. If steady arcing occurs at the spark plug
cables, but the engine will not start, connect the DRB
II diagnostic scan tool. Refer to the Powertrain Diag-
nostic Procedures service manual.

FAILURE TO START TEST


To prevent unnecessary diagnostic time and wrong
IGNITION SECONDARY CIRCUIT DIAGNOSIS
test results, the previous Checking For Spark test
CHECKING FOR SPARK should be performed prior to this test.

CAUTION: When disconnecting a high voltage cable WARNING: SET PARKING BRAKE OR BLOCK THE
from a spark plug or from the distributor cap, twist DRIVE WHEELS BEFORE PROCEEDING WITH THIS
the rubber boot slightly (1/2 turn) to break it loose. TEST.
Grasp the boot (not the cable) and pull it off with a
steady, even force. (1) Unplug the ignition coil harness connector at
the coil (Figs. 17 or 18).
(1) Disconnect the ignition coil secondary cable
from center tower of the distributor cap. Hold the
cable terminal approximately 12 mm (1/2 in.) from a
good engine ground (Fig. 16).

Fig. 17 Coil Harness Connector—4.0L


Engine—Typical
(2) Connect a set of small jumper wires (18 gauge
Fig. 16 Checking for Spark—Typical
or smaller) between the ignition coil and coil electrical
WARNING: BE VERY CAREFUL WHEN THE ENGINE connector (Fig. 19).
IS CRANKING. DO NOT PUT YOUR HANDS NEAR
8D - 14 IGNITION SYSTEMS Z

Fig. 20 PCM 60-Way Connector


(6) Make the special jumper shown in Figure 21.
Using the jumper, momentarily ground terminal-19
of the 60-way connector. A spark should be generated
at the coil cable when the ground is removed.

Fig. 18 Coil Harness Connector—5.2L


Engine—Typical

Fig. 21 Special Jumper Ground-to-Coil Negative


Terminal
(7) If spark is generated, replace the powertrain
control module (PCM).
(8) If spark is not seen, use the special jumper to
ground the coil negative terminal directly.
Fig. 19 Coil Terminals—Typical (9) If spark is produced, repair wiring harness for
an open condition.
(3) Determine that sufficient battery voltage (12.4 (10) If spark is not produced, replace the ignition
volts) is present for the starting and ignition systems. coil.
(4) Crank the engine for 5 seconds while monitor-
ing the voltage at the coil positive terminal (Fig. 19): IGNITION TIMING
• If the voltage remains near zero during the entire Base (initial) ignition timing is NOT adjust-
period of cranking, refer to On-Board Diagnostics in able on any of the 4.0L 6 cylinder or 5.2L V-8
Group 14, Fuel Systems. Check the powertrain con- engines. Do not attempt to adjust ignition tim-
trol module and auto shutdown relay. ing by rotating the distributor.
• If voltage is at near battery voltage and drops to All ignition timing functions are controlled by the
zero after 1-2 seconds of cranking, check the camshaft powertrain control module (PCM). Refer to On-Board
position sensor-to-powertrain control module circuit. Diagnostics in the Multi-Port Fuel Injection—General
Refer to On-Board Diagnostics in group 14, Fuel Sys- Diagnosis section of Group 14, Fuel Systems for more
tems. information. Also refer to the appropriate Powertrain
• If voltage remains at near battery voltage during Diagnostics Procedures service manual for operation
the entire 5 seconds, turn the key off. Remove the of the DRB II Scan Tool.
60-way connector (Fig. 20) from the powertrain con-
trol module (PCM). Check 60-way connector for any INTAKE MANIFOLD CHARGE AIR TEMPERATURE
spread terminals. SENSOR TEST
(5) Remove test lead from the coil positive termi- To perform a complete test of this sensor and its
nal. Connect an 18 gauge jumper wire between the circuitry, refer to the DRB II diagnostic scan tool. Also
battery positive terminal and the coil positive termi- refer to the appropriate Powertrain Diagnostics Pro-
nal. cedures manual. To test the sensor only, refer to the
following:
Z IGNITION SYSTEMS 8D - 15

(1) Disconnect the wire harness connector from the SENSOR RESISTANCE (OHMS)
sensor (Figs. 22 or 23).

Fig. 22 Air Temperature Sensor—4.0L Engine

refer to the appropriate Powertrain Diagnostics Pro-


cedures manual. To test the sensor only, refer to the
following:
4.0L Engines: The MAP sensor is located on the
cowl panel near the rear of the engine valve cover
(Fig. 24).

Fig. 23 Air Temperature Sensor—5.2L


Engine—Typical
(2) Test the resistance of the sensor with a input
impedance (digital) volt-ohmmeter. Do not remove the
sensor from the engine for testing. For resistance
values, refer to the Sensor Resistance chart. Replace
the sensor if it is not within the range of resistance
specified in the chart.
(3) Test the resistance of the wire harness. This is
done between the Powertrain Control Module (PCM)
wire harness connector terminal-2 and the sensor Fig. 24 MAP Sensor—4.0L Engine
connector terminal. Also check continuity between 5.2L Engine: The MAP sensor is located on the
terminal-4 to the sensor connector terminal. Repair front of the throttle body (Fig. 25).
the wire harness as necessary if the resistance is (1) 4.0L Engine: Inspect the sensor vacuum hose
greater than 1 ohm. connections at the throttle body and sensor (Fig. 25).
Repair as necessary.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 5.2L Engines: Inspect the L-shaped rubber fitting
TEST located between the MAP sensor and throttle body
To perform a complete test of this sensor and its (Fig. 26).
circuitry, refer to the DRB II diagnostic scan tool. Also
8D - 16 IGNITION SYSTEMS Z

Fig. 27 MAP Sensor Test—Typical


voltage should be approximately 5 volts (60.5V). Five
Fig. 25 MAP Sensor—5.2L Engine volts (60.5V) should also be at terminal-6 of the
corresponding Powertrain Control Module (PCM) wire
harness connector. Repair or replace the wire harness
as necessary.
(5) Test the sensor ground circuit at sensor connec-
tor terminal-A and PCM connector terminal-4. Repair
the wire harness if necessary.
(6) Test the sensor ground circuit at the PCM con-
nector between terminal-4 and terminal-11 with an
ohmmeter. If the ohmmeter indicates an open circuit,
inspect for a defective sensor ground connection. Re-
fer to Group 8W, Wiring for location of ground connec-
tion. If the ground connection is good, replace the
PCM. If terminal-4 has a short circuit to 12 volts,
correct this condition before replacing the PCM.

POWERTRAIN CONTROL MODULE (PCM)


Fig. 26 MAP Sensor Rubber Fitting—5.2L Engine The PCM (formerly called the SBEC or engine con-
CAUTION: When testing the sensor, be sure that the troller) is located in the right/rear side of the engine
harness wires are not damaged by the test meter compartment.
probes. The ignition system is controlled by the PCM.
For removal and installation of this component,
(2) Test the sensor output voltage at the sensor refer to the Component Removal/Installation section
connector between terminals A and B as marked on of this group.
the sensor body (Fig. 27). This is done with the igni- For diagnostics, refer to the appropriate Powertrain
tion switch ON and the engine OFF. Output voltage Diagnostic Procedures service manual for operation of
should be 4-to-5 volts. The voltage should drop to the DRB II scan tool.
1.5-to-2.1 volts with a hot, neutral idle speed
condition. SPARK PLUGS
(3) Test Powertrain Control Module (PCM) For spark plug removal, cleaning, gap adjustment
terminal-1 for the same voltage described above to and installation, refer to the Component
verify the wire harness condition. Repair as neces- Removal/Installation section of this group.
sary. 5.2L Engine: Spark plug heat shields are pressed
(4) Test sensor supply voltage at sensor connector into the cylinder head to surround each spark plug
between terminals A and C with the ignition ON. The cable boot and spark plug (Fig. 28). These shields
Z IGNITION SYSTEMS 8D - 17

protect the spark plug boots from damage (due to


intense engine heat generated by the exhaust mani-
folds) and should not be removed. After the spark
plug cable has been installed, the lip of the cable boot
should have a small air gap to the top of the heat
shield (Fig. 28).

Fig. 29 Normal Operation and Cold (Carbon) Fouling


causes the entire tip of the spark plug to be coated
with a rust colored deposit. This rust color can be
misdiagnosed as being caused by coolant in the com-
bustion chamber. Spark plug performance is not af-
fected by MMT deposits.
Fig. 28 Heat Shields—5.2L Engine
COLD FOULING/CARBON FOULING
Faulty carbon and/or gas fouled plugs generally
cause hard starting, but they will clean up at higher Cold fouling is sometimes referred to as carbon
engine speeds. Faulty plugs can be identified in a fouling. The deposits that cause cold fouling are basi-
number of ways: poor fuel economy, power loss, de- cally carbon (Fig. 29). A dry, black deposit on one or
crease in engine speed, hard starting and, in general, two plugs in a set may be caused by sticking valves or
poor engine performance. defective spark plug cables. Cold (carbon) fouling of
Remove the spark plugs and examine them for the entire set of spark plugs may be caused by a
burned electrodes and fouled, cracked or broken por- clogged air filter or repeated short operating times
celain insulators. Keep plugs arranged in the order in (short trips).
which they were removed from the engine. An iso-
lated plug displaying an abnormal condition indicates ELECTRODE GAP BRIDGING
that a problem exists in the corresponding cylinder. Electrode gap bridging may be traced to loose de-
Replace spark plugs at the intervals recommended in posits in the combustion chamber. These deposits ac-
the maintenance chart in Group 0, Lubrication and cumulate on the spark plugs during continuous stop-
Maintenance. and-go driving. When the engine is suddenly
Spark plugs that have low mileage may be cleaned subjected to a high torque load, deposits partially
and reused if not otherwise defective. Refer to the liquefy and bridge the gap between electrodes (Fig.
following Spark Plug Condition section of this group. 30). This short circuits the electrodes. Spark plugs
with electrode gap bridging can be cleaned using
CONDITION standard procedures.
NORMAL OPERATING SCAVENGER DEPOSITS
The few deposits present on the spark plug will
Fuel scavenger deposits may be either white or
probably be light tan or slightly gray in color. This is
yellow (Fig. 31). They may appear to be harmful, but
evident with most grades of commercial gasoline (Fig.
this is a normal condition caused by chemical addi-
29). There will not be evidence of electrode burning.
tives in certain fuels. These additives are designed to
Gap growth will not average more than approxi-
mately 0.025 mm (.001 in) per 1600 km (1000 miles) change the chemical nature of deposits and decrease
of operation. Spark plugs that have normal wear can spark plug misfire tendencies. Notice that accumula-
usually be cleaned, have the electrodes filed, have the tion on the ground electrode and shell area may be
gap set and then be installed. heavy, but the deposits are easily removed. Spark
Some fuel refiners in several areas of the United plugs with scavenger deposits can be considered nor-
States have introduced a manganese additive (MMT) mal in condition and can be cleaned using standard
for unleaded fuel. During combustion, fuel with MMT procedures.
8D - 18 IGNITION SYSTEMS Z

Fig. 30 Electrode Gap Bridging Fig. 32 Chipped Electrode Insulator

Fig. 31 Scavenger Deposits Fig. 33 Preignition Damage


CHIPPED ELECTRODE INSULATOR SPARK PLUG OVERHEATING
A chipped electrode insulator usually results from Overheating is indicated by a white or gray center
bending the center electrode while adjusting the electrode insulator that also appears blistered (Fig.
spark plug electrode gap. Under certain conditions, 34). The increase in electrode gap will be considerably
severe detonation can also separate the insulator in excess of 0.001 inch per 1000 miles of operation.
from the center electrode (Fig. 32). Spark plugs with This suggests that a plug with a cooler heat range
this condition must be replaced. rating should be used. Over advanced ignition timing,
detonation and cooling system malfunctions can also
PREIGNITION DAMAGE
cause spark plug overheating.
Preignition damage is usually caused by excessive
combustion chamber temperature. The center elec- SPARK PLUG SECONDARY CABLES
trode dissolves first and the ground electrode dis- 5.2L Engine: Spark plug heat shields are pressed
solves somewhat latter (Fig. 33). Insulators appear into the cylinder head to surround each spark plug
relatively deposit free. Determine if the spark plug cable boot and spark plug (Fig. 35). These shields
has the correct heat range rating for the engine.
protect the spark plug boots from damage (due to
Determine if ignition timing is over advanced, or if
intense engine heat generated by the exhaust mani-
other operating conditions are causing engine over-
folds) and should not be removed. After the spark
heating. (The heat range rating refers to the operat-
plug cable has been installed, the lip of the cable boot
ing temperature of a particular type spark plug.
Spark plugs are designed to operate within specific should have a small air gap to the top of the heat
temperature ranges. This depends upon the thickness shield (Fig. 35).
and length of the center electrodes porcelain insula-
tor.)
Z IGNITION SYSTEMS 8D - 19

When testing secondary cables for damage with an


oscilloscope, follow the instructions of the equipment
manufacturer.
If an oscilloscope is not available, spark plug cables
may be tested as follows:

CAUTION: Do not leave any one spark plug cable


disconnected for longer than necessary during test-
ing. This may cause possible heat damage to the
catalytic converter. Total test time must not exceed
ten minutes.

With the engine not running, connect one end of a


test probe to a good ground. Start the engine and run
the other end of the test probe along the entire length
of all spark plug cables. If cables are cracked or
Fig. 34 Spark Plug Overheating punctured, there will be a noticeable spark jump from
the damaged area to the test probe. The cable run-
ning from the ignition coil to the distributor cap can
be checked in the same manner. Cracked, damaged or
faulty cables should be replaced with resistance type
cable. This can be identified by the words ELEC-
TRONIC SUPPRESSION printed on the cable jacket.
Use an ohmmeter to test for open circuits, excessive
resistance or loose terminals. Remove the distributor
cap from the distributor. Do not remove cables
from cap. Remove cable from spark plug. Connect
ohmmeter to spark plug terminal end of cable and to
corresponding electrode in distributor cap. Resistance
should be 250 to 1000 Ohms per inch of cable. If not,
remove cable from distributor cap tower and connect
ohmmeter to the terminal ends of cable. If resistance
is not within specifications as found in the Spark
Plug Cable Resistance chart, replace the cable. Test
Fig. 35 Heat Shields—5.2L Engine all spark plug cables in this manner.
TESTING To test ignition coil-to-distributor cap cable, do not
Spark plug cables are sometimes referred to as remove the cable from the cap. Connect ohmmeter to
secondary ignition cables or secondary wires. The
SPARK PLUG CABLE RESISTANCE
cables transfer electrical current from the distributor
to individual spark plugs at each cylinder. The spark
plug cables are of nonmetallic construction and have
a built in resistance. The cables provide suppression
of radio frequency emissions from the ignition system.
Check the high-tension cable connections for good
contact at the ignition coil, distributor cap towers and
spark plugs. Terminals should be fully seated. The
terminals and spark plug covers should be in good rotor button (center contact) of distributor cap and
condition. Terminals should fit tightly to the ignition terminal at ignition coil end of cable. If resistance is
coil, distributor cap and spark plugs. The spark plug not within specifications as found in the Spark Plug
cover (boot) of the cable should fit tight around the Cable Resistance chart, remove the cable from the
spark plug insulator. Loose cable connections can distributor cap. Connect the ohmmeter to the termi-
cause corrosion and increase resistance, resulting in nal ends of the cable. If resistance is not within
shorter cable service life. specifications as found in the Spark Plug Cable Resis-
Clean the high tension cables with a cloth moist- tance chart, replace the cable. Inspect the ignition coil
ened with a nonflammable solvent and wipe dry. tower for cracks, burns or corrosion.
Check for brittle or cracked insulation.
8D - 20 IGNITION SYSTEMS Z

For removal and installation of spark plug cables,


refer to Spark Plug Secondary Cables in the Compo-
nent Removal/Installation section.

THROTTLE POSITION SENSOR TEST


To perform a complete test of this sensor and its
circuitry, refer to the DRB II diagnostic scan tool. Also
refer to the appropriate Powertrain Diagnostics Pro-
cedures manual. To test the sensor only, refer to the
following:
The throttle position sensor can be tested with a
digital voltmeter. The center terminal of the sensor
connector is the output terminal (Figs. 36 or 37).

Fig. 37 Sensor Testing—5.2L Engine


center terminal wire of the connector. Check this at
idle (throttle plate closed) and at wide open throttle
(WOT). At idle, sensor output voltage should be
greater than 200 millivolts. At wide open throttle,
sensor output voltage must be less than 4.8 volts. The
output voltage should increase gradually as the
throttle plate is slowly opened from idle to WOT.
Fig. 36 Sensor Testing—4.0L Engine
With the ignition key in the ON position and engine OXYGEN SENSOR TESTS
not running, check the sensor output voltage at the For diagnosis, removal or installation, refer to
Group 14, Fuel Systems in this manual.
Z IGNITION SYSTEMS 8D - 21

COMPONENT REMOVAL/INSTALLATION

INDEX
page page

Automatic Shut Down (ASD) Relay .. . . . . . . . . . . 21 Intake Manifold Charge Air Temperature Sensor . . 29
Camshaft Position Sensor . . . . . . .. . . . . . . . . . . 21 Manifold Absolute Pressure (MAP) Sensor . . . . . . 29
Crankshaft Position Sensor . . . . . .. . . . . . . . . . . 22 Oxygen (O2) Sensor . . . . . . . . . . . . . . . . . . . . . . . 30
Distributor . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 25 Powertrain Control Module (PCM) . . . . . . . . . . . . . 30
Engine Coolant Temperature Sensor . . . . . . . . . . . 24 Spark Plug Secondary Cables . . . . . . . . . . . . . . . 32
General Information . . . . . . . . . . . .. . . . . . . . . . . 21 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Ignition Coil . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 28 Throttle Position Sensor (TPS) . . . . . . . . . . . . . . . 33

GENERAL INFORMATION INSTALLATION


This section of the group, Component (1) Push the relay into the connector.
Removal/Installation, will discuss the removal and (2) Install the relay cover.
installation of ignition system components.
For basic ignition system diagnostics and service CAMSHAFT POSITION SENSOR
adjustments, refer to the Diagnostics/Service Proce- The camshaft position sensor is located in the dis-
dures section of this group. tributor.
For system operation and component identification,
refer to the Component Identification/System Opera- REMOVAL—4.0L ENGINE
tion section of this group. (1) Remove the distributor. Refer to Distributor Re-
moval.
AUTOMATIC SHUT DOWN (ASD) RELAY (2) Remove the distributor rotor.
The ASD relay is installed in the Power Distribu-
tion Center (PDC) (Fig. 1). Relay location is printed CAUTION: Do not position the distributor in a vise
on the PDC cover. when removing or installing the drive gear roll pin.
Support the distributor with wooden blocks.

(3) Mark the position of the gear and the shaft in


line with the roll pin. The gear MUST be installed
back to its original position on the distributor shaft.
(4) Using a small pin punch and hammer, remove
the distributor gear roll (spring) pin (Fig. 2).

Fig. 1 Power Distribution Center


REMOVAL Fig. 2 Distributor Gear—Removal/Installation—4.0L
(1) Remove the Power Distribution Center cover. Engine
(2) Remove the relay by lifting straight up. (5) Lightly tap the end of the distributor shaft until
distributor gear and thrust washer are removed.
8D - 22 IGNITION SYSTEMS Z

(6) Slide the distributor shaft out of the distributor


housing.
(7) Remove the camshaft position sensor mounting
screw and positioning arm (Fig. 3).

Fig. 4 Engine Firing Order—5.2L Engine

Fig. 3 Camshaft Position Sensor—4.0L Engine


(8) Slide the wire harness grommet out of the dis-
tributor housing. Remove the camshaft position sen-
sor.

INSTALLATION—4.0L ENGINE
(1) Position the camshaft position sensor in the
distributor housing. Place the wire harness grommet Fig. 5 Camshaft Position Sensor—5.2L Engine
into the opening in the distributor housing. (5) Remove distributor rotor from distributor shaft.
(2) Install retaining arm and retaining screw. (6) Lift the camshaft position sensor assembly from
(3) Install distributor shaft into distributor hous- the distributor housing (Fig. 5).
ing. Make sure the upper thrust washer is installed
on the shaft. INSTALLATION—5.2L ENGINE
(4) Position thrust washer and drive gear on dis- (1) Install camshaft position sensor to distributor.
tributor shaft. Align sensor into notch on distributor housing.
(5) Note the previous CAUTION and install dis- (2) Connect wiring harness.
tributor drive gear roll pin. (3) Install rotor.
(6) Install rotor. (4) Install distributor cap. Tighten mounting
(7) Install distributor. screws.
(5) Install spark plug cables in correct firing order
REMOVAL—5.2L ENGINE
(Fig. 4) to distributor cap. Be sure all spark plug
Distributor removal is not necessary to remove
cables are firmly connected into distributor cap tow-
camshaft position sensor.
ers.
(1) Disconnect negative battery cable at battery.
(2) Remove coil high-tension cable and all spark
plug cables at distributor cap. Note and mark position
CRANKSHAFT POSITION SENSOR
of cables (Fig. 4) before removal. REMOVAL—4.0L ENGINE
(3) Remove distributor cap from distributor (two The crankshaft position sensor is mounted to the
screws). transmission bellhousing at the left/rear side of the
(4) Disconnect camshaft position sensor wiring har- engine block (Fig. 6).
ness from main engine wiring harness.
Z IGNITION SYSTEMS 8D - 23

Fig. 6 Crankshaft Position Sensor—4.0L Engine


(1) Near the rear of the intake manifold, disconnect
the pigtail harness on the sensor from the main elec-
trical harness.
(2) Raise and support the vehicle.
Fig. 7 Crankshaft Position Sensor—5.2L Engine
(3) Remove the two sensor mounting bolts (Fig. 6).
(4) Remove the sensor.
(5) Remove clip from sensor wire harness.

INSTALLATION—4.0L ENGINE
(1) Install the sensor flush against the opening in
the transmission housing.
(2) Install and tighten the two sensor mounting
bolts to 19 NIm (14 ft. lbs.) torque.

CAUTION: The two bolts used to secure the sensor


to the transmission are specially machined to cor-
rectly space the unit to the flywheel. Do not attempt
to install any other bolts.

(3) Lower the vehicle.


(4) Connect the electrical connector to the sensor.
(5) Install clip on sensor wire harness. Fig. 8 Exhaust Manifold Heat Shield—5.2L Engine
REMOVAL—5.2L ENGINE (6) Disconnect electrical connector at engine oil
The sensor is bolted to the top of the cylinder block pressure sending unit.
near the rear of right cylinder head (Fig. 7). (7) To prevent damage to oil pressure sending unit,
(1) Remove the spark plug cable loom and spark a special tool, such as number C-4597 must be used
plug cables from valve cover mounting stud at rear of (Fig. 9). Remove sending unit from engine.
right valve cover (Fig. 7). Position spark plug cables (8) Loosen EGR tube mounting nut at intake mani-
to top of valve cover. fold (Fig. 7).
(2) Remove the right exhaust manifold heat shield (9) Remove 2 EGR tube mounting bolts at exhaust
nuts/bolts and remove heat shield (Fig. 8). manifold (Fig. 7) and remove EGR tube. Discard old
(3) Disconnect 2 hoses at Exhaust Gas Recircula- gasket at exhaust manifold.
tion (EGR) valve. Note position of hoses at EGR valve (10) Disconnect crankshaft position sensor pigtail
before removal. harness from main wiring harness.
(4) Disconnect electrical connector and hoses at
(11) Remove 2 sensor (recessed hex head) mounting
electric EGR transducer (EET). Note position of hoses
bolts (Fig. 7) and remove sensor.
at EET before removal.
(5) Remove 2 EGR valve mounting bolts (Fig. 7)
and remove EGR valve. Discard old EGR gasket.
8D - 24 IGNITION SYSTEMS Z

ENGINE COOLANT TEMPERATURE SENSOR


WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR. RE-
FER TO GROUP 7, COOLING.

REMOVAL—4.0L ENGINE
The sensor is installed in the thermostat housing
(Fig. 10) on 4.0L engines.

Fig. 9 Oil Pressure Sending Unit—Removal/Installation


INSTALLATION—5.2L ENGINE
(1) Position crankshaft position sensor to engine
and install mounting bolts. Tighten bolts to 8 NIm
(70 in. lbs.) torque.
(2) Connect main harness electrical connector to
sensor. Fig. 10 Coolant Temperature Sensor—4.0L Engine
(3) Clean the EGR tube and exhaust manifold (at (1) Drain cooling system until the coolant level is
EGR tube mounting point) of any old gasket material. below the cylinder head. For cooling system draining,
(4) Install a new gasket to exhaust manifold end of refer to Group 7, Cooling.
EGR tube and install EGR tube to both manifolds. (2) Disconnect the coolant temperature sensor wire
Tighten tube mounting nut at intake manifold. connector.
Tighten 2 mounting bolts at exhaust manifold to 23 (3) Remove the sensor from the thermostat housing
NIm (204 in. lbs.) torque. (Fig. 10).
(5) Coat the threads of the oil pressure sending
unit with thread sealant. Do not allow any of the INSTALLATION—4.0L ENGINE
thread sealant to get into the sending unit opening, or (1) Install coolant temperature sensor into the ther-
the opening at the engine. Install sending unit to mostat housing. Tighten to 28 NIm (21 ft. lbs.)
engine and tighten to 14 NIm (130 in. lbs.) torque. torque.
Install electrical connector to sending unit. (2) Connect the wire connector.
(6) Clean the intake manifold and EGR valve of (3) Fill the cooling system. Refer to group 7, Cool-
any old gasket material. ing System.
(7) Install a new EGR valve gasket at intake mani-
fold. REMOVAL—5.2L ENGINE
(8) Install EGR valve to intake manifold. Tighten 2
WARNING: HOT, PRESSURIZED COOLANT CAN
EGR bolts to 23 NIm (200 in. lbs.) torque.
CAUSE INJURY BY SCALDING. COOLING SYSTEM
(9) Position EET and install its electrical connector.
MUST BE PARTIALLY DRAINED BEFORE REMOV-
Connect hoses between EGR valve and EET. Connect
ING THE COOLANT TEMPERATURE SENSOR. RE-
hose between main vacuum harness and EET.
FER TO GROUP 7, COOLING.
(10) Install spark plug cable loom and spark plug
cables to valve cover mounting stud. The engine coolant temperature sensor on the 5.2L
(11) Install heat shield at right exhaust manifold. engine is located in a water passage of the intake
manifold next to the thermostat housing (Fig. 11).
Z IGNITION SYSTEMS 8D - 25

Fig. 11 Coolant Temperature Sensor—5.2L Engines


(1) Partially drain cooling system. Refer to Group
7, Cooling.
(2) Disconnect electrical connector from sensor (Fig.
11).
(3) Engines with air conditioning: When removing
the connector from sensor, do not pull directly on
wiring harness. Fabricate an L-shaped hook tool from
a coat hanger (approximately eight inches long). Place
the hook part of tool under the connector for removal.
The connector is snapped onto the sensor. It is not
equipped with a lock type tab.
(4) Remove sensor from intake manifold. Fig. 12 Distributor—4.0L Engine—Typical

INSTALLATION—5.2L ENGINE
(1) Install sensor.
(2) Tighten to 7 NIm (5.5 ft. lbs.) torque.
(3) Connect electrical connector to sensor.
The sensor connector is symmetrical (not indexed).
It can be installed to the sensor in either direction.
(4) Replace any lost engine coolant. Refer to Group
7, Cooling System.

DISTRIBUTOR
All distributors contain an internal oil seal that
prevents oil from entering the distributor housing.
The seal is not serviceable. The camshaft position
sensor is located in the distributor on all engines.

REMOVAL—4.0L ENGINE
(1) Disconnect the negative battery cable at the
battery.
(2) Scribe a mark on the distributor housing. Do
this below the left side of (past) the number one spark
plug cable post of the distributor cap. This will be Fig. 13 Mark Distributor Housing—4.0L Engine
used as a reference for number 1 cylinder firing posi-
tion (Fig. 13). with zero on front cover timing scale (Fig. 14).
(3) Remove the distributor cap. The timing mark is on the edge of vibration
(4) Turn the engine crankshaft in a clockwise direc- damper closest to engine timing chain cover.
tion until rotor is approaching scribe mark on dis- (5) Align the trailing edge of the rotor blade with
tributor housing. Then slowly turn engine until tim- the scribe mark on the distributor housing (Fig. 15).
ing mark on crankshaft vibration damper lines up
8D - 26 IGNITION SYSTEMS Z

Fig. 16 Align Oil Pump Gear Shaft—4.0L Engine


(2) Install the rotor.
(3) Without engaging the distributor gear into the
cam gear, position the distributor into the hole in the
engine block. Be sure the distributor gasket is in-
stalled.
(4) Visually line up the holddown ear of the dis-
tributor housing with the holddown clamp hole (Fig.
Fig. 14 Align Timing Marks—4.0L Engine 17).
(6) Remove the distributor holddown bolt and

Fig. 17 Distributor Installation—4.0L Engine


(5) Turn the rotor to the 4 o’clock position (Fig. 18).
Fig. 15 Align Rotor Trailing Edge With Scribe (6) Slide the distributor down into the block until it
Mark—4.0L Engine seats. Keep the holddown ear aligned to the hole in
clamp. the block.
(7) Remove the distributor from the engine. (7) The rotor should be in the 5 o’clock position.
This is with the trailing edge of rotor blade lined up
INSTALLATION—4.0L ENGINE with scribe mark on distributor housing (number one
(1) Using a flat blade screwdriver, turn the oil spark plug cable post location).
pump gear shaft. Do this until the slot is slightly past (8) Install the distributor holddown clamp bolt and
the 11 o’clock position (Fig. 16). tighten to 23 NIm (17 ft. lbs.) torque.
The oil pump shaft is located down in the distribu-
tor hole.
Z IGNITION SYSTEMS 8D - 27

Fig. 19 Engine Firing Order—5.2L Engine

Fig. 18 Rotor Alignment—4.0L Engine


(9) Install the distributor cap and connect the dis-
tributor electrical connector.
(10) Connect battery cable to battery.

REMOVAL—5.2L ENGINE

CAUTION: Base ignition timing is not adjustable on


the 5.2L V-8 engine. Distributors do not have built in
centrifugal or vacuum assisted advance. Base igni-
tion timing and timing advance are controlled by the
Powertrain Control Module (PCM). Because a con- Fig. 20 Damper-To-Timing Chain Cover Alignment
ventional timing light can not be used to adjust Marks—5.2L Engine
distributor position after installation, note position
of distributor before removal. camshaft position sensor (Fig. 21). If not, rotate the
crankshaft through another complete 360 degree
(1) Disconnect negative battery cable at battery. turn. Note the position of the number one cylinder
(2) Remove coil high-tension cable and all spark spark plug cable (on the cap) in relation to rotor.
plug cables at distributor cap. Note and mark position Rotor should now be aligned to this position.
of cables (Fig. 19) before removal. (8) Disconnect camshaft position sensor wiring har-
(3) Remove distributor cap from distributor (two ness from main engine wiring harness.
screws). (9) Remove distributor rotor from distributor shaft.
(4) Mark the position of distributor housing in rela- (10) Remove distributor holddown clamp bolt and
tionship to engine or dash panel. This is done to aid clamp (Fig. 22). Remove distributor from vehicle.
in installation.
Before distributor is removed, the number one cyl- CAUTION: Do not crank engine with distributor re-
inder must be brought to the top dead center (TDC) moved. Distributor/crankshaft relationship will be
firing position. lost.
(5) Attach a socket to the Crankshaft Vibration
Damper mounting bolt.
(6) Slowly rotate engine clockwise, as viewed from INSTALLATION—5.2L ENGINE
front, until indicating mark on crankshaft vibration If engine has been cranked while distributor is re-
damper is aligned to 0 degree (TDC) mark on timing moved, establish the relationship between distributor
chain cover (Fig. 20). shaft and number one piston position as follows:
(7) The distributor rotor should now be aligned to Rotate crankshaft in a clockwise direction, as
the CYL. NO. 1 alignment mark (stamped) into the viewed from front, until number one cylinder piston
8D - 28 IGNITION SYSTEMS Z

(9) Install distributor cap. Tighten mounting


screws.
(10) Install spark plug cables in correct firing order
(Fig. 19) to distributor cap. Be sure all spark plug
cables are firmly connected into distributor cap tow-
ers.

IGNITION COIL
The ignition coil is an epoxy filled type. If the coil is
replaced, it must be replaced with the same type.

REMOVAL—4.0L ENGINE
The ignition coil is mounted to the right side of the
4.0L engine block next to the distributor (Fig. 23).

Fig. 21 Rotor Alignment Mark—5.2L Engine

Fig. 23 Ignition Coil—4.0L Engine


(1) Disconnect the ignition coil secondary cable
Fig. 22 Distributor Holddown Clamp—5.2L Engine from ignition coil (Fig. 23).
is at top of compression stroke (compression should be (2) Disconnect engine harness connector from igni-
felt on finger with number one spark removed). Then tion coil.
continue to slowly rotate engine clockwise until indi- (3) Remove ignition coil mounting screws. Remove
cating mark (Fig. 20) is aligned to 0 degree (TDC) coil.
mark on timing chain cover.
(1) Clean top of cylinder block for a good seal be- INSTALLATION—4.0L ENGINE
tween distributor base and block. (1) Install ignition coil to bracket on cylinder block
(2) Lightly oil the rubber O-ring seal on the dis- with mounting screws.
tributor housing. (2) Connect engine harness connector to coil.
(3) Install rotor to distributor shaft. (3) Connect ignition coil cable to ignition coil.
(4) Position distributor into engine to its original
position. Engage tongue of distributor shaft with slot REMOVAL—5.2L ENGINE
in distributor oil pump drive gear. Position rotor to The ignition coil is mounted to a bracket near the
the number one spark plug cable position. front of the right engine cylinder head on 5.2L en-
(5) Install distributor holddown clamp and clamp gines (Fig. 24).
bolt. Do not tighten bolt at this time. (1) Disconnect the wiring and secondary cable from
(6) Rotate the distributor housing until rotor is the ignition coil (Fig. 24).
aligned to CYL. NO. 1 alignment mark on the cam-
shaft position sensor (Fig. 21).
(7) Tighten clamp holddown bolt (Fig. 22) to 22.5
NIm (200 in. lbs.) torque.
(8) Connect camshaft position sensor wiring har-
ness to main engine harness.
Z IGNITION SYSTEMS 8D - 29

Fig. 24 Ignition Coil—5.2L Engine—Typical Fig. 25 Air Temperature Sensor—4.0L Engine


WARNING: DO NOT REMOVE THE COIL MOUNTING
BRACKET-TO-CYLINDER HEAD MOUNTING BOLTS.
THE COIL MOUNTING BRACKET IS UNDER ACCES-
SORY DRIVE BELT TENSION. IF THIS BRACKET IS
TO BE REMOVED FOR ANY REASON, ALL BELT
TENSION MUST FIRST BE RELIEVED. REFER TO
THE BELT SECTION OF GROUP 7, COOLING SYS-
TEM.

(2) Remove ignition coil from coil mounting bracket


(two bolts).

INSTALLATION—5.2L ENGINE
(1) Install the ignition coil to coil bracket. If nuts
and bolts are used to secure coil to coil bracket,
tighten to 11 NIm (100 in. lbs.) torque. If the coil
mounting bracket has been tapped for coil mounting Fig. 26 Air Temperature Sensor—5.2L
bolts, tighten bolts to 5 NIm (50 in. lbs.) torque. Engine—Typical
(2) Connect all wiring to ignition coil.
(1) Disconnect electrical connector at sensor (Fig.
INTAKE MANIFOLD CHARGE AIR TEMPERATURE 26).
SENSOR (2) Remove sensor from intake manifold.

REMOVAL—4.0L ENGINE INSTALLATION—5.2L ENGINE


The intake manifold charge air temperature sensor (1) Install sensor to intake manifold. Tighten the
is installed into the intake manifold plenum (Fig. 25) sensor to 13 NIm (10 ft. lbs.) torque.
on the 4.0L engine. (2) Install electrical connector.
(1) Disconnect the electrical connector from the
sensor. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
(2) Remove the sensor from the intake manifold.
REMOVAL—4.0L ENGINE
INSTALLATION—4.0L ENGINE The sensor is located on the cowl panel near the
(1) Install the air temperature sensor into the in- rear of the engine valve cover (Fig. 27) if equipped
take manifold. Tighten the sensor to 13 NIm (10 ft. with the 4.0L engine.
lbs.) torque. (1) Disconnect the sensor electrical connector (Fig.
(2) Connect the electrical connector to the sensor. 27).
(2) Disconnect the sensor vacuum supply hose.
REMOVAL—5.2L ENGINE (3) Remove the two sensor mounting screws and
The charge air temperature sensor is located in remove sensor from vehicle.
right-front side of intake manifold (Fig. 26) on the
5.2L engine.
8D - 30 IGNITION SYSTEMS Z

Fig. 27 MAP Sensor—4.0L Engine Fig. 29 MAP Sensor Rubber Fitting—5.2L Engine
INSTALLATION—4.0L ENGINE (2) Remove throttle body. Refer to Throttle Body
(1) Install sensor to cowl panel. Install 2 screws removal in the Group 14, Fuel System section of this
and tighten to 3 NIm (25 in. lbs.) torque. manual.
(2) Install the sensor vacuum supply hose. (3) Remove two MAP sensor mounting screws (Fig.
(3) Connect the sensor electrical connector. 29).
(4) While removing MAP sensor, slide the L-shaped
REMOVAL—5.2L ENGINE
rubber vacuum fitting (Fig. 29) from the throttle body.
The MAP sensor is located on the front of the
(5) Remove rubber fitting from MAP sensor.
throttle body (Fig. 28) if equipped with the 5.2L en-
gine. INSTALLATION—5.2L ENGINE
An L-shaped rubber fitting is used to connect the (1) Install L-shaped rubber fitting to MAP sensor.
MAP sensor to throttle body (Fig. 29).
(2) Position MAP sensor to throttle body while
guiding L-shaped rubber fitting over throttle body
fitting.
(3) Install MAP sensor mounting screws. Tighten
screws to 3 NIm (25 in. lbs.) torque.
(4) Install throttle body. Refer to Throttle Body in-
stallation in the Group 14, Fuel System section of this
manual.
(5) Install air intake tube.

OXYGEN (O2) SENSOR


For diagnostics and removal/installation proce-
dures, refer to Group 14, Fuel Systems, in this
manual.

POWERTRAIN CONTROL MODULE (PCM)


The PCM is located on the cowl panel in the
right/rear side of the engine compartment (Fig. 30).

REMOVAL
(1) Disconnect the negative battery cable at the
battery.
(2) Remove the coolant reserve/overflow bottle (one
Fig. 28 MAP Sensor—5.2L Engine bolt and two nuts) (Fig. 31)
The throttle body must be removed from the intake (3) Loosen the 60-Way connector mounting bolt
manifold for MAP sensor removal. (Fig. 32).
(1) Remove air intake tube at throttle body. (4) Remove the electrical connector by pulling
straight back.
Z IGNITION SYSTEMS 8D - 31

Fig. 30 PCM Location Fig. 32 PCM Mounting


(5) Connect negative cable to battery.

SPARK PLUGS
5.2L ENGINE. Spark plug cable heat shields are
pressed into the cylinder head to surround each cable
boot and spark plug (Fig. 33). These shields protect
the spark plug boots from damage (due to intense
engine heat generated by the exhaust manifolds) and
should not be removed. After the spark plug cable has
been installed, the lip of the cable boot should have a
small air gap to the top of the heat shield (Fig. 33).
If removal of the heat shield(s) is necessary, remove
the spark plug cable and compress the sides of shield
for removal. Each shield is slotted to allow for

Fig. 31 Coolant Reserve/Overflow Bottle Mounting


(5) Remove the three PCM mounting bolts (Fig.
32).
(6) Remove PCM.

INSTALLATION
(1) Check the pins in the PCM 60-way electrical
connector for damage. Repair as necessary.
(2) Install PCM. Tighten three mounting bolts to 1
NIm (9 in. lbs.) torque.
(3) Engage 60-way connector into PCM. Tighten
connector mounting bolt to 4 NIm (35 in. lbs.) torque.
Fig. 33 Heat Shields—5.2L Engine
(4) Install coolant reserve/overflow bottle (Fig. 31).
8D - 32 IGNITION SYSTEMS Z

compression and removal. To install the shields, align PLUG INSTALLATION


shield to machined opening in cylinder head and tap Always tighten spark plugs to the specified torque.
into place with a block of wood. Over tightening can cause distortion. This may result
in a change in the spark plug gap.
PLUG REMOVAL When replacing the spark plug and ignition coil
(1) Always remove spark plug or ignition coil cables cables, route the cables correctly and secure them in
by grasping at the cable boot. Turn the cable boot 1/2 the appropriate retainers. Failure to route the cables
turn and pull straight back in a steady motion. Never properly can cause the radio to reproduce ignition
pull directly on the cable. Internal damage to cable noise. It could cause cross ignition of the spark plugs,
will result. or short circuit the cables to ground.
(2) Prior to removing the spark plug, spray com- (1) Start the spark plug into the cylinder head by
pressed air around the spark plug hole and the area hand to avoid cross threading.
around the spark plug. This will help prevent foreign (2) Tighten the spark plugs to 35-41 NIm (26-30 ft.
material from entering the combustion chamber. lbs.) torque.
(3) Remove the spark plug using a quality socket (3) Install spark plug cables over spark plugs.
with a rubber or foam insert.
(4) Inspect the spark plug condition. Refer to Spark SPARK PLUG SECONDARY CABLES
Plugs in the Diagnostics/Service Procedures section of
this group. CAUTION: When disconnecting a high voltage cable
from a spark plug or from the distributor cap, twist
PLUG CLEANING the rubber boot slightly (1/2 turn) to break it loose.
The plugs may be cleaned using commercially avail- Grasp the boot (not the cable) and pull it off with a
able spark plug cleaning equipment. After cleaning, steady, even force.
file the center electrode flat with a small point file or
jewelers file before adjusting gap. Install cables into the proper engine cylinder firing
order (Figs. 35 or 36).
PLUG GAP ADJUSTMENT
Check the spark plug gap with a gap gauge tool. If
the gap is not correct, adjust it by bending the ground
electrode (Fig. 34). Never attempt to adjust the
gap by bending the center electrode.

SPARK PLUG GAP


• 4.0L Engine Spark Plug Gap: .89 mm (.035 in).
• 5.2L Engine Spark Plug Gap: .89 mm (.035 in).

Fig. 35 Engine Firing Order—4.0L Engine


When replacing the spark plug and coil cables,
route the cables correctly and secure in the proper
retainers. Failure to route the cables properly can
cause the radio to reproduce ignition noise. It could
also cause cross ignition of the plugs, or short circuit
the cables to ground.
When installing new cables, make sure a positive
connection is made. A snap should be felt when a good
connection is made between the plug cable and the
distributor cap tower.
5.2L Engine: Spark plug cable boot heat shields
are pressed into the cylinder head to surround each
cable boot and spark plug (Fig. 37). These shields
Fig. 34 Setting Spark Plug Gap—Typical protect the spark plug boots from damage (due to in-
Z IGNITION SYSTEMS 8D - 33

Fig. 36 Engine Firing Order—5.2L Engine Fig. 38 TPS—4.0L Engine


tense engine heat generated by the exhaust mani-
folds) and should not be removed. After the spark
plug cable has been installed, the lip of the cable boot
should have a small air gap to the top of the heat
shield (Fig. 37).

Fig. 39 TPS Installation—4.0L Engine


(2) Connect sensor electrical connector to sensor.
(3) Operate the throttle by hand to check for bind-
ing.
Fig. 37 Heat Shields—5.2L Engine REMOVAL—5.2L ENGINE
THROTTLE POSITION SENSOR (TPS) The TPS is located on the side of the throttle body
(Fig. 40) on the 5.2L engine.
REMOVAL—4.0L ENGINE (1) Remove air intake tube at throttle body.
The throttle position sensor is mounted to the (2) Disconnect TPS electrical connector (Fig. 40).
throttle body (Fig. 38) on the 4.0L engine. (3) Remove two TPS mounting screws (Fig. 41).
(1) Disconnect sensor electrical connector.
(4) Remove TPS from throttle body.
(2) Remove the two sensor mounting screws.
(3) Remove sensor. INSTALLATION—5.2L ENGINE
The throttle shaft end of the throttle body slides
INSTALLATION—4.0L ENGINE
into a socket in the TPS (Fig. 42). The TPS must be
The throttle shaft end slides into a socket in the
sensor (Fig. 39). The sensor must be installed so that installed so that it can be rotated a few degrees. If the
it can be rotated a few degrees. (If the sensor will not sensor will not rotate, install the sensor with the
rotate, install the sensor with the throttle shaft on throttle shaft on the other side of the socket tangs.
the other side of the socket tangs). The sensor will be The TPS will be under slight tension when rotated.
under slight tension when rotated. (1) Install the TPS and two retaining screws.
(1) Install the throttle position sensor and two re- (2) Tighten screws to 7 NIm (60 in. lbs.) torque.
taining screws.
8D - 34 IGNITION SYSTEMS Z

Fig. 41 TPS Mounting Screws—5.2L Engine

Fig. 40 TPS—5.2L Engine


(3) Manually operate the throttle control lever by
hand to check for any binding of the TPS.
(4) Connect TPS electrical connector to TPS.
(5) Install air intake tube.

Fig. 42 TPS Installation—5.2L Engine


Z IGNITION SYSTEMS 8D - 35

IGNITION SWITCH

INDEX
page page

General Information . . . . . . . . . . . . . . . . . . . . . . . 35 Ignition Switch and Key Cylinder Service . . . . . . . 35

GENERAL INFORMATION
The ignition switch is located in the steering col-
umn. The Key-In-Switch and Halo Light are integral
with the ignition switch. Refer to Group 8M for Key-
In-Switch and Halo Light diagnosis.

IGNITION SWITCH AND KEY CYLINDER SERVICE


REMOVAL
(1) Disconnect negative battery cable.
(2) Tilt column: Remove tilt lever (counterclock-
wise).
(3) Remove upper and lower covers (three screws).
(4) Remove ignition switch mounting screws
(Snap-on torx bit tool TTXR20B0 or equivalent
required—Fig. 1).
Fig. 2 Key in Switch and Halo Lamp Connector

Fig. 1 Ignition Switch Screw Removal


(5) Gently pull switch away from the column. Re-
lease two connector locks on the 7-terminal wiring
connector. Remove the connector from the ignition
switch.
(6) Release connector lock on the Key-In-Switch
and Halo Light 4-terminal connector. Remove the con-
Fig. 3 Key Cylinder Retaining Pin
nector from the ignition switch (Fig. 2).
(7) Remove the key cylinder from the ignition (b) Rotate the key clockwise to the OFF position.
switch as follows: The key cylinder should now be unseated from the
ignition switch assembly (Fig. 4).
(a) With the key inserted and the ignition switch
in the lock position, proceed as follows: Use a small CAUTION: Do not remove key cylinder at this time.
screwdriver to depress the key cylinder retaining
pin flush with the key cylinder surface (Fig. 3). (c) With key cylinder in unseated position (key
cylinder bezel about 1/8 inch above ignition switch
8D - 36 IGNITION SYSTEMS Z

serted into park-lock link contour slot. Tighten retain-


ing screws to 2 NIm (17 in. lbs.) torque.

Fig. 6 Ignition Switch View From Column

Fig. 4 Unseated Key Cylinder


halo light ring), proceed as follows: Rotate the key
counterclockwise to the Lock position and remove
the key.
(d) Remove key cylinder (Fig. 5).

Fig. 7 Ignition Switch Mounting Pad


(3) Assemble cover to the column (3 screws).
Tighten retaining screws to 2 NIm (17 in. lbs.)
torque.
(4) Tilt column: Install tilt lever (clockwise).
(5) Install negative battery cable.
(6) Install key cylinder.
(a) With key cylinder and ignition in lock posi-
tion, gently insert key cylinder into ignition switch
Fig. 5 Key Cylinder Removal assembly until it bottoms.
INSTALLATION (b) Insert key. While gently pushing on the key
(1) Install electrical connectors to switch. Make cylinder (inward) toward the ignition switch, rotate
sure that the switch locking tabs are fully seated in key clockwise to end of travel.
the wiring connectors. (7) Check for proper operation of push-to-lock, halo
(2) Mount ignition switch to the column (Fig. 6). lighting, Accessory, Lock, Off, Run, Start, column lock
Park-lock dowel pin on ignition switch assembly and shift lock (if applicable).
must engage with column park-lock slider linkage
(Fig. 7). Verify ignition switch is in lock position (flag
is parallel with the ignition switch terminals) (Fig. 6).
Apply a dab of grease to flag and pin. Position park-
lock link and slider to mid-travel. Position ignition
switch against lock housing face. Be sure pin is in-
Z IGNITION SYSTEMS 8D - 37

IGNITION SWITCH CIRCUITS


8D - 38 IGNITION SYSTEMS Z

SPECIFICATIONS
GENERAL INFORMATION SPARK PLUG CABLE RESISTANCE
The following specifications are published from the
latest information available at the time of publica-
tion. If anything differs between the specifica-
tions found on the Vehicle Emission Control
Information (VECI) label and the following spec-
ifications, use specifications on VECI label. The
VECI label is located in the engine compartment.
SPARK PLUGS

IGNITION COIL RESISTANCE


Z IGNITION SYSTEMS 8D - 39

ENGINE FIRING ORDER—4.0L ENGINE TORQUE

ENGINE FIRING ORDER—5.2L ENGINE